US20120043849A1 - Stator for electric rotating machine and method for manufacturing the same - Google Patents
Stator for electric rotating machine and method for manufacturing the same Download PDFInfo
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- US20120043849A1 US20120043849A1 US13/204,041 US201113204041A US2012043849A1 US 20120043849 A1 US20120043849 A1 US 20120043849A1 US 201113204041 A US201113204041 A US 201113204041A US 2012043849 A1 US2012043849 A1 US 2012043849A1
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- teeth
- stator core
- stator
- chamfered
- arcuated
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/12—Impregnating, heating or drying of windings, stators, rotors or machines
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
Definitions
- the present disclosure relates to a stator for an electric rotating machine used as an electric motor or a generator in vehicles, for example, and a method for manufacturing the same.
- a stator of an electric rotating machine equipped with a circular-shaped stator core that has a plurality of slots arranged in a circumferential direction and a stator coil wound around the slots of the stator core is generally known.
- the stator core is constituted to have a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction.
- the stator coil is fixed to the stator core by using an impregnant, such as varnish, for example.
- stator core As a kind of stator core, there is a stator core that is not provided with flange portions projecting in the circumferential direction at tips of the teeth in order to raise a space factor of the coil in the slots.
- stator core is usually constituted by a plurality of steel plates laminated in an axial direction of the core, if a corner part where a projected tip surface and a side surface of the teeth that abut is formed in straight-like planes when punching the steel plate by pressing, burrs are easily formed in the corner part.
- the burrs formed in the corner part become a bank, and the impregnant that remains on the inner circumferential surface (the projected tip surface of the teeth) of the stator core can easily adhere.
- the impregnant adheres to the inner circumferential surface of the stator core as a hardened material, it interferes with a perimeter part of the rotor disposed at the inner circumferential side of the stator core, and the problems such as a deterioration of the ease of assembly at the time of inserting the rotor and the impregnant being shaved off with the rotor such that it becomes a foreign substance damaging the structures, such as the stator coil and a gear, occurs.
- An embodiment provides a stator for an electric rotating machine and a method for manufacturing the same that suppresses an occurrence of burrs at a curved corner part formed in both ends in a circumferential direction of a projected tip surface of teeth, and reduces an amount of adhesion of an impregnant to an inner circumferential surface of a stator core.
- the stator for the electric rotating machine includes a circular stator core that has a plurality of slots arranged in a circumferential direction, a stator coil wound around the slots of the stator core, and an impregnant applied to the inner circumferential surface of the stator core.
- the stator core has a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction.
- the teeth that have chamfered surfaces and ones that do not have chamfered surfaces are intermingled between a projected tip surface and each side surfaces of the teeth.
- At least one of curved corner parts formed in a circumferential direction at both ends of the projected tip surface of the teeth is formed in an arcuated shape.
- R 1 represents a curvature radius of arcuated surfaces formed in the curved corner part where the projected tip surface and the chamfered surface abut
- R 2 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the side surface abut.
- At least one of the curved corner parts formed in the circumferential direction at both ends of the projected tip surface of the teeth is formed in the arcuated shape.
- the amount of the adhered impregnant that remained and adhered to the inner circumferential surface of the stator core can be reduced since it becomes easy for the impregnant to flow through into the slots from the projected tip surface of the teeth when the impregnant is applied to the inner circumferential surface of the stator core from the inner circumferential side of the stator core.
- the teeth having the chamfered surface have a longer gap length between the rotors compared with the teeth having no chamfered surface, and magnetic resistance at the time of magnetic flux passes becomes large.
- the amount of magnetic flux that passes through the teeth can be adjusted by stationing the teeth having the chamfered surface in a changing position of the teeth in the same phases in the stator coil or in the changing position of the teeth between different phases in the stator coil.
- robustness against formation of burrs is securable by configuring the value of the curvature radius R 1 larger than that of the curvature radius R 2 .
- the teeth with the chamfered surfaces are stationed in a changing position of the teeth between different phases in the stator coil.
- the curved corner part is a part where the projected tip surface and the chamfered surface or the side surface abut.
- the curved corner parts formed in the arcuated shape are arranged in the same side in the circumferential direction of the teeth at an entire circumferences of the stator core.
- both of the curved corner parts formed in the circumferential direction at both ends of the projected tip surface of the teeth are formed in the arcuated shape.
- the chamfered surface is formed in the arcuated surface that extends outwards in a radial direction.
- no flange portions projecting in the circumferential direction are disposed on the side surfaces of the projected tip parts of the teeth.
- a method for manufacturing the stator for the electric rotating machine having a circular stator core that has a plurality of slots arranged in a circumferential direction, a stator coil wound around the slots of the stator core, and an impregnant applied to the inner circumferential surface of the stator core.
- the stator core has a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction;
- the teeth that have chamfered surfaces and ones that do not have chamfered surfaces between a projected tip surface and each side surfaces of the teeth are intermingled.
- the method has steps of forming at least one of curved corner parts formed in a circumferential direction at both ends of the projected tip surface of the teeth in an arcuated surface, and configuring a value of R 1 to be larger than a value of R 2 (R 1 >R 2 ) when R 1 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the chamfered surface abut and R 2 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the side surface abut.
- FIG. 1 shows a schematic sectional view in an axial direction of a composition of an electric rotating machine according to an embodiment
- FIG. 2A shows a plan view of a stator
- FIG. 2B shows an elevational view of the stator seen from a side according to the embodiment
- FIG. 3 shows a plan view of a stator core according to the embodiment
- FIG. 4A shows a plan view of a divided core
- FIG. 4B shows an enlarged part A of FIG. 4A
- FIG. 4C shows an enlarged part B of FIG. 4A ;
- FIGS. 5A and 5B show explanatory schematic views of application process of an impregnant according to the embodiment
- FIG. 5A shows a sectional view where the stator is cut in an axial direction
- FIG. 5B shows a partial perspective view of a part of the stator
- FIG. 6 shows a graph of a relation between a change rate of NV compelling force of the electric rotating machine and a curvature radius R 1 according to the embodiment
- FIG. 7 shows a graph of a relation between a change rate of torque of the electric rotating machine and the curvature radius R 1 according to the embodiment.
- FIG. 8 shows a partial plan view of a tip part of teeth of the stator core according to a modification.
- an electric rotating machine 1 of the present embodiment has a housing 10 , a rotor 14 , and a stator 20 .
- the housing 10 is formed by joining openings of a pair of housing components 10 a and 10 b that has substantially a bottomed cylindrical shape.
- the rotor 14 fixed to a rotating shaft 13 supported rotatably by the housing 10 via bearings 11 and 12 .
- the stator 20 is fixed to the housing 10 in a position that surrounds the rotor 14 inside the housing 10 .
- the rotor 14 is formed by arranging a permanent magnet in an outer circumferential side of the stator 20 that faces an inner circumferential side.
- a plurality of poles having different magnetic properties of the permanent magnet are arranged in a circumferential direction alternately.
- the number of the magnetic poles of the rotor 14 is not limited because it varies with the electric rotating machine.
- the rotor with eight poles (4 N poles, 4 S poles) is used in the present embodiment.
- the stator 20 has a stator core 30 formed by a plurality of divided cores 32 , and a 3-phase stator coil 40 formed from a plurality of lead wires as shown in FIG. 2A and FIG. 2B .
- insulating paper may be disposed between the stator core 30 and the stator coil 40 .
- stator core 30 is explained with reference to FIG. 3 and FIGS. 4A to 4C .
- the stator core 30 is formed in a circular shape with the plurality of divided cores 32 (24 pieces in the present embodiment) divided in the circumferential direction, and has a plurality of slots 31 arranged in an inner circumferential side in the circumferential direction of the stator core 30 .
- the stator core 30 is formed by a circular-shaped back core part 33 located in an outer circumferential side of the stator core 30 and a plurality of teeth 34 projecting from the back core part 33 inwardly in a radial direction while arranged in the circumferential direction with a predetermined separation.
- the slots 31 that open to the inner circumferential side of the stator core 30 and extend in the radial direction is formed between side surfaces 34 a of the adjoining teeth 34 that face each other in the circumferential direction.
- the side surfaces 34 a of the adjoining teeth 34 that face each other in the circumferential direction, i.e., a pair of side surfaces 34 a in which a single slot 31 is divided, are parallel mutually.
- each slot 31 is extended in the radial direction with a fixed width size in the circumferential direction.
- the slots 31 are formed at a rate of two per 1 phase of the stator coil 40 to a number of the magnetic poles (8) of a rotor since the stator coil 40 is a distributed winding of a double slot in the present embodiment.
- the 48 slots 31 are formed by the same number of the 48 teeth 34 as the slots 31 .
- the 48 teeth 34 that have chamfered surfaces 34 c (henceforth “the chamfered teeth 34 A”) and ones that do not have chamfered surfaces 34 c (henceforth “the non-chamfered teeth 34 B”) between a projected tip surface 34 b and each side surfaces 34 a , are intermingled as shown in FIGS. 4A to 4C .
- the chamfered teeth 34 A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40 .
- the chamfered surfaces 34 c are formed between the projected tip surface 34 b and each side surfaces 34 a in the chamfered teeth 34 A.
- the two curved corner parts 34 d where the projected tip surface 34 b and each chamfered surface 34 c abut are formed in arcuated surfaces with a curvature radius R 1 .
- both of the curved corner parts 34 d formed in the circumferential direction at both ends of the projected tip surface 34 b of the teeth 34 are formed as arcuated surfaces.
- two curved corner parts 34 e where the side surfaces 34 a and the chamfered surface 34 c abut are not made into arcuated surfaces, but are in the state where approximately straight-like planes abut.
- two curved corner parts 34 f where the projected tip surface 34 b and each side surfaces 34 a abut in the non-chamfered teeth 34 B are formed in arcuated surfaces with a curvature radius R 2 smaller than that of the curvature R 1 of the curved corner parts 34 d.
- both of the curved corner parts 34 f formed in the circumferential direction at both ends of the projected tip surface 34 b of the teeth 34 are formed in the arcuated shape like the chamfered teeth 34 A.
- the divided cores 32 that constitute the stator core 30 are formed by laminating a plurality of electromagnetic steel sheets in an axial direction of the stator core 30 .
- the steel sheets are formed in a predetermined form by press punching.
- stator core 30 is fixed (shape retained) in a circular shape by an outer cylinder 37 fitted to an outer circumference of the divided core 32 arranged in a circular shape (refer to FIG. 2 ).
- the stator coil 40 is formed by at first forming a belt-like lead wire assembly by laminating a predetermined number (12 in the present embodiment) of lead wires formed in a predetermined wave-shape in a predetermined state, and then the lead wire assembly is wound spirally in a cylindrical shape.
- the lead wires that constitutes the stator coil 40 is formed in the wave-shaped form that have slot accommodation parts disposed in the slots 31 of the stator core 30 , and turn parts that connect the slot accommodation parts accommodated in the slots 31 from which the circumferential directions differ in outside of the slot 31 .
- the lead wires adopt a rectangular wire with an insulation coating made by a conductor with a rectangle section and an insulation film that coats an outer circumference of the conductor.
- Assembling of the stator coil 40 and the stator core 30 is performed as follows. First, the teeth 34 of each divided cores 32 are inserted into the stator coil 40 from the outer circumferential side of the stator coil 40 . Next, all the divided cores 32 are arranged in a circular form along with the stator coil 40 . Finally, the cylindrical outer cylinder 37 is fitted to the outer circumference of the divided core 32 .
- stator coil 40 is assembled to the state where the predetermined slot accommodation part of each lead wire is accommodated in the predetermined slot 31 of the stator core 30 , as shown in FIG. 2 .
- the turn parts that connect the adjoining slot accommodation parts of the lead wires are projected from the both end sides 30 a in an axial direction of the stator core 30 , and coil ends are formed in both ends of the stator coil 40 in an axial direction by a large number of the projected turn parts.
- a fixation of the stator coil 40 to the stator core 30 is performed by applying the impregnant.
- the stator core 30 is held by a holding part 61 first so that the axial direction of the stator core 30 becomes horizontal.
- the impregnant 63 is applied throughout the inner circumferential surface of the stator core 30 by dripping the impregnant 63 from a discharging part 62 to the inner circumferential surface (the projected tip surface 34 b of the teeth 34 ) from the inner circumferential side of the stator core 30 .
- the NV compelling force means an exciting force that generates magnetic noise.
- an outside diameter of the stator core 30 is 230 mm
- an inner diameter is 150 mm
- a length in the axial direction is 50 mm
- a thickness of the electromagnetic steel sheet that constitutes the stator core 30 is 0.3 mm.
- At least one of the curved corner parts 34 d , 34 f formed in the circumferential direction at both ends of the projected tip surface 34 b of the teeth 34 is formed in the arcuated shape.
- the amount of the adhered impregnant 63 that remains and adheres to the inner circumferential surface of the stator core 30 can be reduced since it becomes easy for the impregnant 63 to flow through into the slot 31 from the projected tip surface 34 b of the teeth when the impregnant 63 is applied to the inner circumferential surface of the stator core 30 from the inner circumferential side of the stator core 30 .
- both of the curved corner parts 34 d , 34 f formed in the circumferential direction at both ends of the projected tip surface 34 b are formed in the arcuated shape, the redundancy at the time of assembling the stator core 30 and the stator coil 40 improves.
- the chamfered teeth 34 A and the non-chamfered teeth 34 B are intermingled, and the chamfered teeth 34 A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40 .
- the NV compelling force can be reduced since the amount of magnetic flux that passes through the teeth 34 can be adjusted.
- the arcuated surfaces formed in the curved corner part 34 d of the chamfered teeth 34 A is configured larger than the curvature radius R 2 of the arcuated surfaces formed in the curved corner part 34 f of the non-chamfered teeth 34 B, robustness against formation of burrs is securable.
- the chamfered teeth 34 A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40 in the embodiment mentioned above, the teeth 34 may be stationed in the changing position within the same phase.
- both of the curved corner parts 34 d , 34 f formed in the circumferential direction at both ends of the projected tip surface 34 b of the teeth 34 are formed in the arcuated shape
- one of the curved corner parts 34 d , 34 f formed in the circumferential direction at one end may be formed in the arcuated surface.
- the curved corner parts 34 d , 34 f formed in the arcuated shape are preferred to be arranged in the same side in the circumferential direction of the teeth 34 at the entire circumferences of the stator core 30 .
- the impregnant 63 applied can be infiltrated certainly into the slots 31 from the projected tip surface 34 b of the teeth 34 , since the curved corner parts 34 d , 34 f formed in the arcuated shape are to be positioned in the back side of the rotating direction when applying the impregnant 63 to the inner circumferential surface from the inner circumferential side of the stator core 30 while rotating the stator core 30 .
- the chamfered surface 34 c of the chamfered teeth 34 A is formed in a flat plane in the embodiment mentioned above, the chamfered surface 34 c may be formed in the arcuated shape that extends outwards in a radial direction as shown in FIG. 8 .
Abstract
Description
- This application is based on and claims the benefit of priority from earlier Japanese Patent Application No. 2010-176352 filed Aug. 5, 2010, the description of which is incorporated herein by reference.
- The present disclosure relates to a stator for an electric rotating machine used as an electric motor or a generator in vehicles, for example, and a method for manufacturing the same.
- Conventionally, a stator of an electric rotating machine equipped with a circular-shaped stator core that has a plurality of slots arranged in a circumferential direction and a stator coil wound around the slots of the stator core is generally known.
- The stator core is constituted to have a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction.
- In order to secure a resistance against vibration of the stator coil in such a stator, the stator coil is fixed to the stator core by using an impregnant, such as varnish, for example.
- An impregnating method of infiltrating the impregnant into the slots of the stator core by dripping the impregnant on an end part of the coil is disclosed in JP-A-2003-189523.
- By the way, as a kind of stator core, there is a stator core that is not provided with flange portions projecting in the circumferential direction at tips of the teeth in order to raise a space factor of the coil in the slots.
- When the impregnating method disclosed in the JP-A-2003-189523 is adopted in such a stator core, a radially most inner side coil of the stator coil cannot be fixed firmly to the stator core.
- That is because, since the flange portions are not provided in an inner side in a radial direction of the radially most inner side coil, there is no place where the impregnant can collect.
- Then, in order for the radially most inner side coil to be fixed firmly, it is considered that the impregnant is dropped to an inner circumferential surface from the inner circumferential side of the stator core so that the impregnant is infiltrated into the slots, however, the following problems occur in such a case.
- Although the stator core is usually constituted by a plurality of steel plates laminated in an axial direction of the core, if a corner part where a projected tip surface and a side surface of the teeth that abut is formed in straight-like planes when punching the steel plate by pressing, burrs are easily formed in the corner part.
- Therefore, if the impregnant is applied to the inner circumferential surface from the inner circumferential side of the stator core, the burrs formed in the corner part become a bank, and the impregnant that remains on the inner circumferential surface (the projected tip surface of the teeth) of the stator core can easily adhere.
- Thus, if the impregnant adheres to the inner circumferential surface of the stator core as a hardened material, it interferes with a perimeter part of the rotor disposed at the inner circumferential side of the stator core, and the problems such as a deterioration of the ease of assembly at the time of inserting the rotor and the impregnant being shaved off with the rotor such that it becomes a foreign substance damaging the structures, such as the stator coil and a gear, occurs.
- Moreover, as other problems raised by the presence of the burrs, since it becomes easy for cooling oil to contact the teeth surface at the time of oil-cooling of the cooling oil supplied to the inside of the electric rotating machine, causing of worsening of power loss as resistance is mentioned when rotating the rotor.
- An embodiment provides a stator for an electric rotating machine and a method for manufacturing the same that suppresses an occurrence of burrs at a curved corner part formed in both ends in a circumferential direction of a projected tip surface of teeth, and reduces an amount of adhesion of an impregnant to an inner circumferential surface of a stator core.
- In a stator for an electric rotating machine according to a first aspect, the stator for the electric rotating machine includes a circular stator core that has a plurality of slots arranged in a circumferential direction, a stator coil wound around the slots of the stator core, and an impregnant applied to the inner circumferential surface of the stator core.
- The stator core has a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction.
- The teeth that have chamfered surfaces and ones that do not have chamfered surfaces are intermingled between a projected tip surface and each side surfaces of the teeth.
- At least one of curved corner parts formed in a circumferential direction at both ends of the projected tip surface of the teeth is formed in an arcuated shape.
- A relationship (R1>R2) is satisfied, where R1 represents a curvature radius of arcuated surfaces formed in the curved corner part where the projected tip surface and the chamfered surface abut and R2 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the side surface abut.
- Accordingly, at least one of the curved corner parts formed in the circumferential direction at both ends of the projected tip surface of the teeth is formed in the arcuated shape.
- Therefore, when punching a steel plate that constitutes the stator core, occurrence of burrs in the curved corner parts formed in the arcuated shape is suppressed.
- Thereby, the amount of the adhered impregnant that remained and adhered to the inner circumferential surface of the stator core can be reduced since it becomes easy for the impregnant to flow through into the slots from the projected tip surface of the teeth when the impregnant is applied to the inner circumferential surface of the stator core from the inner circumferential side of the stator core.
- Moreover, since surfaces of the teeth become difficult to cover with cooling oil at the time of cooling the cooling oil supplied to the inside of the electric rotating machine, frictional resistance in a gap between the rotor and the stator core can be reduced when rotating the rotor, thus reduction of loss can be achieved.
- Furthermore, degradation of the cooling oil by frictional heat can also be prevented.
- Furthermore, the teeth having the chamfered surface have a longer gap length between the rotors compared with the teeth having no chamfered surface, and magnetic resistance at the time of magnetic flux passes becomes large.
- Thereby, the amount of magnetic flux that passes through the teeth can be adjusted by stationing the teeth having the chamfered surface in a changing position of the teeth in the same phases in the stator coil or in the changing position of the teeth between different phases in the stator coil.
- As a result, an exciting force that generates magnetic noise (NV compelling force) can be reduced.
- Moreover, robustness against formation of burrs is securable by configuring the value of the curvature radius R1 larger than that of the curvature radius R2.
- In the stator for the electric rotating machine according to a second aspect, the teeth with the chamfered surfaces are stationed in a changing position of the teeth between different phases in the stator coil.
- In the stator for the electric rotating machine according to a third aspect, the curved corner part is a part where the projected tip surface and the chamfered surface or the side surface abut.
- In the stator for the electric rotating machine according to a fourth aspect, the curved corner parts formed in the arcuated shape are arranged in the same side in the circumferential direction of the teeth at an entire circumferences of the stator core.
- In the stator for the electric rotating machine according to a fifth aspect, both of the curved corner parts formed in the circumferential direction at both ends of the projected tip surface of the teeth are formed in the arcuated shape.
- In the stator for the electric rotating machine according to a sixth aspect, the chamfered surface is formed in the arcuated surface that extends outwards in a radial direction.
- In the stator for the electric rotating machine according to a seventh aspect, no flange portions projecting in the circumferential direction are disposed on the side surfaces of the projected tip parts of the teeth.
- In a method for manufacturing the stator for the electric rotating machine according to a eighth aspect, a method is presented for manufacturing the electric rotating machine having a circular stator core that has a plurality of slots arranged in a circumferential direction, a stator coil wound around the slots of the stator core, and an impregnant applied to the inner circumferential surface of the stator core.
- The stator core has a plurality of teeth projecting inwardly in a radial direction so as to divide the slots on a side of both sides in a circumferential direction; and
- The teeth that have chamfered surfaces and ones that do not have chamfered surfaces between a projected tip surface and each side surfaces of the teeth are intermingled.
- The method has steps of forming at least one of curved corner parts formed in a circumferential direction at both ends of the projected tip surface of the teeth in an arcuated surface, and configuring a value of R1 to be larger than a value of R2 (R1>R2) when R1 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the chamfered surface abut and R2 represents a curvature radius of the arcuated surfaces formed in the curved corner part where the projected tip surface and the side surface abut.
- In the accompanying drawings:
-
FIG. 1 shows a schematic sectional view in an axial direction of a composition of an electric rotating machine according to an embodiment; -
FIG. 2A shows a plan view of a stator, andFIG. 2B shows an elevational view of the stator seen from a side according to the embodiment; -
FIG. 3 shows a plan view of a stator core according to the embodiment; -
FIG. 4A shows a plan view of a divided core,FIG. 4B shows an enlarged part A ofFIG. 4A , andFIG. 4C shows an enlarged part B ofFIG. 4A ; -
FIGS. 5A and 5B show explanatory schematic views of application process of an impregnant according to the embodiment,FIG. 5A shows a sectional view where the stator is cut in an axial direction, andFIG. 5B shows a partial perspective view of a part of the stator, -
FIG. 6 shows a graph of a relation between a change rate of NV compelling force of the electric rotating machine and a curvature radius R1 according to the embodiment; -
FIG. 7 shows a graph of a relation between a change rate of torque of the electric rotating machine and the curvature radius R1 according to the embodiment; and -
FIG. 8 shows a partial plan view of a tip part of teeth of the stator core according to a modification. - With reference to the drawings, hereinafter will be described an embodiment that materialized a stator of an electric rotating machine of the present disclosure.
- As show in
FIG. 1 , an electricrotating machine 1 of the present embodiment has ahousing 10, arotor 14, and astator 20. Thehousing 10 is formed by joining openings of a pair ofhousing components - The
rotor 14 fixed to arotating shaft 13 supported rotatably by thehousing 10 viabearings stator 20 is fixed to thehousing 10 in a position that surrounds therotor 14 inside thehousing 10. - The
rotor 14 is formed by arranging a permanent magnet in an outer circumferential side of thestator 20 that faces an inner circumferential side. A plurality of poles having different magnetic properties of the permanent magnet are arranged in a circumferential direction alternately. - The number of the magnetic poles of the
rotor 14 is not limited because it varies with the electric rotating machine. The rotor with eight poles (4 N poles, 4 S poles) is used in the present embodiment. - The
stator 20 has astator core 30 formed by a plurality of dividedcores 32, and a 3-phase stator coil 40 formed from a plurality of lead wires as shown inFIG. 2A andFIG. 2B . In addition, insulating paper may be disposed between thestator core 30 and thestator coil 40. - Next, the
stator core 30 is explained with reference toFIG. 3 andFIGS. 4A to 4C . - As shown in
FIG. 3 andFIGS. 4A to 4C , thestator core 30 is formed in a circular shape with the plurality of divided cores 32 (24 pieces in the present embodiment) divided in the circumferential direction, and has a plurality ofslots 31 arranged in an inner circumferential side in the circumferential direction of thestator core 30. - The
stator core 30 is formed by a circular-shaped backcore part 33 located in an outer circumferential side of thestator core 30 and a plurality ofteeth 34 projecting from theback core part 33 inwardly in a radial direction while arranged in the circumferential direction with a predetermined separation. - By this, the
slots 31 that open to the inner circumferential side of thestator core 30 and extend in the radial direction is formed between side surfaces 34 a of the adjoiningteeth 34 that face each other in the circumferential direction. - The side surfaces 34 a of the adjoining
teeth 34 that face each other in the circumferential direction, i.e., a pair of side surfaces 34 a in which asingle slot 31 is divided, are parallel mutually. - Thereby, each
slot 31 is extended in the radial direction with a fixed width size in the circumferential direction. - By the way, there are no flange portions projecting in the circumferential direction disposed on the side surfaces 34 a of the projected tip parts of the
teeth 34. - The
slots 31 are formed at a rate of two per 1 phase of thestator coil 40 to a number of the magnetic poles (8) of a rotor since thestator coil 40 is a distributed winding of a double slot in the present embodiment. - That is, the 8×3×2=48 pieces of
slots 31 are formed. In this case, the 48slots 31 are formed by the same number of the 48teeth 34 as theslots 31. - The 48
teeth 34 that have chamferedsurfaces 34 c (henceforth “thechamfered teeth 34A”) and ones that do not have chamferedsurfaces 34 c (henceforth “thenon-chamfered teeth 34B”) between a projectedtip surface 34 b and each side surfaces 34 a, are intermingled as shown inFIGS. 4A to 4C . - In the present embodiment, there are provided 16 pieces of the chamfered
teeth non-chamfered teeth 34B, and singlechamfered teeth 34A is arranged for every twonon-chamfered teeth 34B. - That is, the chamfered
teeth 34A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40. - As shown in
FIG. 4B , the chamfered surfaces 34 c are formed between the projectedtip surface 34 b and each side surfaces 34 a in the chamferedteeth 34A. - In addition, the two
curved corner parts 34 d where the projectedtip surface 34 b and eachchamfered surface 34 c abut are formed in arcuated surfaces with a curvature radius R1. - That is, both of the
curved corner parts 34 d formed in the circumferential direction at both ends of the projectedtip surface 34 b of theteeth 34 are formed as arcuated surfaces. - On the other hand, two
curved corner parts 34 e where the side surfaces 34 a and the chamferedsurface 34 c abut are not made into arcuated surfaces, but are in the state where approximately straight-like planes abut. - Moreover, as shown in
FIG. 4C , twocurved corner parts 34 f where the projectedtip surface 34 b and each side surfaces 34 a abut in thenon-chamfered teeth 34B are formed in arcuated surfaces with a curvature radius R2 smaller than that of the curvature R1 of thecurved corner parts 34 d. - Also in this case, both of the
curved corner parts 34 f formed in the circumferential direction at both ends of the projectedtip surface 34 b of theteeth 34 are formed in the arcuated shape like the chamferedteeth 34A. - In addition, the divided
cores 32 that constitute thestator core 30 are formed by laminating a plurality of electromagnetic steel sheets in an axial direction of thestator core 30. The steel sheets are formed in a predetermined form by press punching. - Moreover, the
stator core 30 is fixed (shape retained) in a circular shape by anouter cylinder 37 fitted to an outer circumference of the dividedcore 32 arranged in a circular shape (refer toFIG. 2 ). - The
stator coil 40 is formed by at first forming a belt-like lead wire assembly by laminating a predetermined number (12 in the present embodiment) of lead wires formed in a predetermined wave-shape in a predetermined state, and then the lead wire assembly is wound spirally in a cylindrical shape. - The lead wires that constitutes the
stator coil 40 is formed in the wave-shaped form that have slot accommodation parts disposed in theslots 31 of thestator core 30, and turn parts that connect the slot accommodation parts accommodated in theslots 31 from which the circumferential directions differ in outside of theslot 31. - The lead wires adopt a rectangular wire with an insulation coating made by a conductor with a rectangle section and an insulation film that coats an outer circumference of the conductor.
- Assembling of the
stator coil 40 and thestator core 30 is performed as follows. First, theteeth 34 of each dividedcores 32 are inserted into thestator coil 40 from the outer circumferential side of thestator coil 40. Next, all the dividedcores 32 are arranged in a circular form along with thestator coil 40. Finally, the cylindricalouter cylinder 37 is fitted to the outer circumference of the dividedcore 32. - Thereby, the
stator coil 40 is assembled to the state where the predetermined slot accommodation part of each lead wire is accommodated in thepredetermined slot 31 of thestator core 30, as shown inFIG. 2 . - In this case, the slot accommodation part of each lead wire is accommodated in the slot 3 in every predetermined number of slots (3-phase×2 pieces (double slot)=six pieces in the present embodiment).
- Moreover, the turn parts that connect the adjoining slot accommodation parts of the lead wires are projected from the both end sides 30 a in an axial direction of the
stator core 30, and coil ends are formed in both ends of thestator coil 40 in an axial direction by a large number of the projected turn parts. - Then, in order to secure a resistance against vibration of the
stator coil 40 attached to thestator core 30, a fixation of thestator coil 40 to thestator core 30 is performed by applying the impregnant. - As shown in
FIG. 5A andFIG. 5B , thestator core 30 is held by a holdingpart 61 first so that the axial direction of thestator core 30 becomes horizontal. - Then, while rotating the
stator core 30 around an axis with a rotating apparatus, the impregnant 63 is applied throughout the inner circumferential surface of thestator core 30 by dripping the impregnant 63 from a dischargingpart 62 to the inner circumferential surface (the projectedtip surface 34 b of the teeth 34) from the inner circumferential side of thestator core 30. - By this, in the either case for the chamfered
teeth 34A and thenon-chamfered teeth 34B, the appliedimpregnant 63 infiltrates smoothly into theslots 31 without collecting in the projectedtip surface 34 b since both of thecurved corner parts tip surface 34 b are formed in the arcuated shape. - Therefore, the amount of the adhered
impregnant 63 that remained and adhered to the inner circumferential surface of thestator core 30 is reduced sharply. - Then, when the impregnant 63 that is infiltrated in the
slots 31 solidifies, the stator coils 40 (slot accommodation parts) in theslots 31 are fixed to thestator core 30, and the resistance against vibration is secured. - By the way, in the
stator 20 of the present embodiment, when influences the NV compelling force and torque are investigated at the time when a value of the curvature radius R1 of thecurved corner part 34 d of the chamferedteeth 34A changes, results shown inFIG. 6 andFIG. 7 are obtained. Here, the NV compelling force means an exciting force that generates magnetic noise. - In this case, an outside diameter of the
stator core 30 is 230 mm, an inner diameter is 150 mm, and a length in the axial direction is 50 mm, while a thickness of the electromagnetic steel sheet that constitutes thestator core 30 is 0.3 mm. - Clearly seen from
FIG. 6 , a change rate of the NV compelling force falls gradually as the value of the curvature radius R1 becomes large. - Therefore, by enlarging the curvature radius R1, the h NV compelling force can be greatly reduced.
- Moreover, clearly seen from
FIG. 7 , a change rate of torque hardly changes even if the value of the curvature radius R1 changes. Therefore, the size of the curvature radius R1 is understood that the sensitivity to torque is small. - According to the
stator 20 of the electricrotating machine 1 of the present embodiment constituted as mentioned above, at least one of thecurved corner parts tip surface 34 b of theteeth 34 is formed in the arcuated shape. - Therefore, when punching the steel plate that constitutes the
stator core 30 by pressing, occurrence of burrs in thecurved corner parts - Thereby, the amount of the adhered
impregnant 63 that remains and adheres to the inner circumferential surface of thestator core 30 can be reduced since it becomes easy for the impregnant 63 to flow through into theslot 31 from the projectedtip surface 34 b of the teeth when the impregnant 63 is applied to the inner circumferential surface of thestator core 30 from the inner circumferential side of thestator core 30. - In particular, with the present embodiment, since both of the
curved corner parts tip surface 34 b are formed in the arcuated shape, the redundancy at the time of assembling thestator core 30 and thestator coil 40 improves. - Furthermore, since a rotating direction of the
stator core 30 is not restricted when applying the impregnant 63 to the inner circumferential surface from the inner circumferential side of thestator core 30 while rotating thestator core 30, versatility improves also by this. - Moreover, since surfaces of the
teeth 34 become difficult to cover with cooling oil at the time of cooling the cooling oil supplied to the inside of the electricrotating machine 1, frictional resistance in a gap between therotor 14 and thestator core 30 can be reduced when rotating therotor 14, thus reduction of loss can be achieved. - Furthermore, degradation of the cooling oil by frictional heat can also be prevented.
- Moreover, in the present embodiment, the chamfered
teeth 34A and thenon-chamfered teeth 34B are intermingled, and thechamfered teeth 34A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40. - By this, the NV compelling force can be reduced since the amount of magnetic flux that passes through the
teeth 34 can be adjusted. - Moreover, in the present embodiment, since the arcuated surfaces formed in the
curved corner part 34 d of the chamferedteeth 34A is configured larger than the curvature radius R2 of the arcuated surfaces formed in thecurved corner part 34 f of thenon-chamfered teeth 34B, robustness against formation of burrs is securable. - It should be appreciated that the present disclosure is not limited to the embodiment mentioned above, but may be variously modified in the range that does not deviate from the meaning of the present disclosure.
- For example, although the
chamfered teeth 34A are stationed in the changing position of the teeth between different phases in the 3-phase stator coil 40 in the embodiment mentioned above, theteeth 34 may be stationed in the changing position within the same phase. - Moreover, although both of the
curved corner parts tip surface 34 b of theteeth 34 are formed in the arcuated shape, one of thecurved corner parts - In such a case, the
curved corner parts teeth 34 at the entire circumferences of thestator core 30. - In this way, the amount of the adhered
impregnant 63 that remained and adhered to the inner circumferential surface of thestator core 30 is surely reduced. - The reason is that the impregnant 63 applied can be infiltrated certainly into the
slots 31 from the projectedtip surface 34 b of theteeth 34, since thecurved corner parts stator core 30 while rotating thestator core 30. - Moreover, although the chamfered
surface 34 c of the chamferedteeth 34A is formed in a flat plane in the embodiment mentioned above, the chamferedsurface 34 c may be formed in the arcuated shape that extends outwards in a radial direction as shown inFIG. 8 . - Thereby, reduction of the NV compelling force can be realized more effectively.
Claims (8)
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JP2010176352A JP5267521B2 (en) | 2010-08-05 | 2010-08-05 | Stator for rotating electrical machine and method for manufacturing the same |
JP2010-176352 | 2010-08-05 |
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Cited By (5)
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FR3020194A1 (en) * | 2014-04-17 | 2015-10-23 | Valeo Equip Electr Moteur | STATOR OF ELECTRIC MACHINE WITH SMALL INPUT RADIUS AND METHOD OF MAKING SAID STATOR CORRESPONDING |
CN105723592A (en) * | 2013-11-08 | 2016-06-29 | 三菱电机株式会社 | Stator for rotary electric machine, and rotary electric machine |
EP2779373A3 (en) * | 2013-03-15 | 2017-11-08 | Ingersoll-Rand Company | Rotating machine with magnetic bearing |
US10855153B2 (en) * | 2019-04-16 | 2020-12-01 | Sf Motors, Inc. | Electric vehicle induction machine |
CN112688442A (en) * | 2020-12-31 | 2021-04-20 | 湖南科技大学 | Optimized design method for noise reduction of stator tooth shoulder chamfer of alternating-current traction motor |
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JP2014195374A (en) * | 2013-03-29 | 2014-10-09 | Mitsubishi Electric Corp | Rotary electric machine and manufacturing method therefor |
CN105322731B (en) * | 2014-07-02 | 2017-12-05 | 东元电机股份有限公司 | The top rake method in stator boots portion |
CN112803630B (en) * | 2021-03-22 | 2021-12-31 | 湖南科技大学 | Noise reduction optimization design method for alternating-current traction motor |
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CN112688442A (en) * | 2020-12-31 | 2021-04-20 | 湖南科技大学 | Optimized design method for noise reduction of stator tooth shoulder chamfer of alternating-current traction motor |
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Also Published As
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US8816562B2 (en) | 2014-08-26 |
JP2012039717A (en) | 2012-02-23 |
JP5267521B2 (en) | 2013-08-21 |
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